Polymer gel electrolytes (PGE) based on polyvinylidene fluoride (PVDF), lithium salts and appropriate solvent systems, developed at Leeds University, have been shown to form tough rigid films with conductivities approaching 10(-2) S cm(-1). A continuous process has now been developed for the construction of rechargeable lithium cells by extruding the PGE as a melt and directly laminating between the anode and cathode electrodes. On cooling, the solid PGE acts as electrolyte and separator and binds the cell laminate together from within requiring no external case. This process has been successfully applied for the fabrication of cells with electrodes developed by SpectraPower Inc. in a commercial process enabling cell laminates with PGE thickness less than 0.1 mm and with energy densities approaching 170 Wh kg(-1). A prototype manufacturing facility has been set up to produce rechargeable cells of high specific capacity and high energy density. Future developments will enable rechargeable lithium ion cells to be produced on a continuous process as flat sheets opening the way for novel battery geometries. (c) 2005 Elsevier B.V. All rights reserved.